Selectively biased tool and methods of using the same

ABSTRACT

A tool including a working portion with a working member, a side surface and an end surface. The working portion includes a passage passing through the side surface and the end surface. At least one seal is adapted to restrict fluid flow through the side surface and the end surface and at least partially defines a pressure chamber. The working member is adapted to be selectively pivotally positioned by selectively pressurizing the pressure chamber. The tool similarly enables unique methods of working workpieces.

REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation-in-part of U.S. ApplicationNo. 09/392,114 filed Sep. 8, 1999, which claims the benefit of U.S.Provisional Application No. 60/099,464 filed Sep. 8, 1998. Thisapplication also claims the benefit of U.S. Provisional Application No.60/265,015 filed Jan. 30, 2001.

TECHNICAL FIELD OF THE INVENTION

[0002] The present invention is directed to an adjustable tool, and moreparticularly to a selectively biased tool and methods of using the same.

BACKGROUND OF THE INVENTION

[0003] A conventional gun reamer tool includes a cutting blade and oneor more support members which are supported at intervals around thecircumference of a rotary shaft (e.g., the reamer head). The shaft,along with the blade and the support members, rotate so that thephysical interference between the rotating blade and the workpiece causea hole to be either bored or reamed in the workpiece. During thismachining operation, the rotating support members are positioned so thatthey support the inside surface of the hole being machined (e.g., eitherreamed or bored) by constraining radially directed motion of the bladerelative to the workpiece.

[0004] In some conventional machining center rotating machine tools,lubricant is supplied to the vicinity of the cutting blade through therotating shaft. An example is shown in U.S. Pat. No. 5,775,853 issued onJul. 7, 1998, the disclosure of which is herein incorporated byreference.

[0005] This support and constraint supplied by the support members helpto control the shape (e.g., cylindricity or circularity) of the hole,and help to maintain a constant alignment of the central axis of thehole along the length of the hole (in other words, the hole isstraighter). For this reason, gun reamers are often used in applicationswhere holes need to be precisely and accurately machined. Such precisionapplications may also be needed in the manufacture of automobile partssuch as cylinder bores in engine blocks, connecting rod bores and pistonwrist pin bores.

[0006] Gun reamers are also especially useful where the hole being cutis relatively long (such as the bore of a gun barrel), because thesupport members will remain in the proximity of the cutting blade, evenwhen the blade has cut a long distance into the workpiece.

[0007] One potential shortcoming of conventional gun reamers is thatthey cannot be adjusted to cut holes of different sizes. Mostconventional gun reamers are designed with support and blade membersrigidly constrained to the reamer head so that the head can cut holes ofjust one predetermined radius. Another potential shortcoming ofconventional gun reamers is that the blade and support members wear atdifferent rates, which can cause seizure or variation in the diameterand/or circularity of the holes cut by the gun reamer.

[0008] In most machine tool operations, including boring and reaming,the friction between the tool and workpiece generates tremendous amountsof heat energy, which can reach temperatures of 2000° F. (1100° C.) andabove. If left uncontrolled, such heat could severely damage (e.g.,cracking or fracturing) the tool, thus reducing its tool life, makingmachine tool operations more dangerous and expensive, and reducing thequality and precision of the workmanship. In addition, heat generatedfriction can discolor the workpiece, and can damage or remove temper orheat treatments. It is commonly known in the industry that coolant canbe introduced to the machining area, such as by spraying, to reducefriction between the tool and workpiece by providing coolant fluidbetween the cutting tool and the workpiece, and to help remove heatenergy generated in machine tool operations.

[0009] Although coolant fluid can be supplied to the machining area, itis often difficult to insure that such fluid actually makes its way tothe interstices between the tool and all of the workpiece surfaces beingmachined. Additionally, fluid can evaporate quickly due to the hightemperatures involved in machining operations. Thus, larger volumes ofcoolant fluid must generally be continuously supplied to the machiningarea for the tool to operate effectively. This need to keep coolantfluid between the tool and wall of the bore hole becomes even moreproblematic in operations where coolant fluids cannot be introduced inclose proximity to the machining areas while the tool is engaged withthe interior surface of the workpiece.

[0010] During use, the work engaging surface of the tool (e.g., thecutting blade and/or support member) can also become loaded withparticles or recently cut chips from the interior surface of theworkpiece, which in turn, reduces the accuracy and effectiveness of thetool through deteriorating machining ability, and/or clogging ofconventional coolant fluid supply openings. It is obviously preferredthat the potential for this undesired loading of particles be reduced,and that any loaded particles be removed from the tool as quickly aspossible. Typically, nozzle arrangements, such as an external cleaningjet, are provided independent of the tool, for injecting coolant fluidat increased velocities toward the work engaging surface and the worksurfaces of the workpiece to wash away particles, to remove particlesalready loaded on the work surface, and to cool the tool and theworkpiece. As mentioned before, it is often very difficult to insurethat the fluid sprayed in this way actually reaches the most criticalareas of the tool/workpiece interface.

[0011] Other attempts to deliver coolant fluid to the machining areahave included air or other pneumatic carriers. As with externallyapplied liquid coolants, when pneumatic carriers are used, resultingturbulence can hinder the machining operations, and often fluid cannotinfiltrate into the actual machining area. Previously, attempts toaddress these two requirements of cooling and cleaning the tool andworkpiece have tended to reduce the accuracy and utility of the tool.

[0012] As can be seen, currently available tools have a number ofshortcomings that can greatly reduce the accuracy of the tools, thetool's life, and its ability to use these tools with automatic toolchanging systems. The current structures and assemblies provide a toolhaving working surfaces that cannot expand to accommodate varying anddifferent uses and needs. Such assemblies can result in unevenmachining, and reduces the assembly's usable life. A need currentlyexists in the machinery industry for a tool with a work engagingassembly having accurately controlled machining diameters so that holesof different sizes can be cut, so that tools cannot become oversized aresult of excessive strokes of the tools, and so that the tool canexpand in a radial direction uniformly and selectively.

SUMMARY OF THE INVENTION

[0013] It is an object of the present invention to provide a cuttingtool that addresses and overcomes the above-mentioned shortcomings andproblems in the machine tool industry.

[0014] It is another object of the present invention to provide acutting tool with support members to support a workpiece, where thesupport member and/or a blade member are selectively biased.

[0015] It is another object of the present invention to provide acutting tool whereby the relative position of the blade and theworkpiece can be controlled by the selective control of the bias of theblade member and/or support member.

[0016] It is yet another object of the present invention to provide acutting tool that has an increased tool life.

[0017] It is also an object of the present invention to provide a toolthat eliminates the need for external coolant fluid jets for cleaning orremoving loaded particles from the tool's machining surface during use,and routes fluid in close proximity to the work engaging surface to washaway recently cut particles.

[0018] It is yet another object of the present invention to provide atool where the workload is reliably distributed over substantially theentire work engaging surface.

[0019] It is another object of the present invention to provide a toolfor accurately and uniformly machining a workpiece.

[0020] It is further an object of the present invention to provide atool that can be selectively adjusted during machine operations.

[0021] Yet another object of the present invention is to provide a toolthat can compensate for material deformation in a workpiece.

[0022] It is still another object of the present invention to provide atool in which coolant fluid delivery to the working area is notinhibited while the tool is engaged with a surface of the workpiece.

[0023] A further object of the present invention is to provide a toolthat can compensate for wear and tear.

[0024] It is yet an object of the present invention to provide a toolthat can be used with a quick change or automatic changeable tool systemhaving a fluid pressure source.

[0025] Still another object of the present invention is to provide atool that can be used to machine holes of different or varyingdiameters.

[0026] It is a further object of the present invention to provide a toolthat continuously, selectively, and controllably delivers coolant fluidto the machining area despite the type of tool engagement.

[0027] Yet another object of the present invention is to provide a toolwhich self regulates itself for wear and tear on the abrasive.

[0028] Still a further object of the present invention is to provide adevice where the work engaging surface can be uniformly varied in aradial direction by selectively applying fluid pressure.

[0029] A further object of the present invention is to provide a toolthat dissipates thermal energy generated in the machining operations,and reduces thermal expansion of the tool.

[0030] Additional objects, advantages and other features of theinvention will be set forth and will become apparent to those skilled inthe art upon examination of the following, or may be learned withpractice of the invention.

[0031] In some exemplary embodiments of the present invention, thesupport member and/or blade member of the cutting tool can beselectively biased by selecting the fluid pressure of a fluid whichbears on the support member and/or blade member. For example, the toolmay be constructed so that pressurized lubricating fluid, which issupplied near or in the vicinity of the cutting blade, bears on andbiases both the blade member and the support member. As anotherexemplary alternative, the blade member and/or the support member may beselectively biased by air pressure and/or by one or more springs.

[0032] In some exemplary embodiments of the present invention, the toolis a reamer which has at least one support member and a blade member,such as a blade cartridge, biased by selectively pressurized fluid. Itis an advantage of these exemplary reamer embodiments that the fluidpressure can be selected to compensate for wear of the blade, and alsoto compensate for the difference in wear between the blade and thesupport member.

[0033] In some exemplary embodiments of the present invention, the toolis a reamer where both the blade member and the support members arebiased by selectively pressurized fluid. In these exemplary reamerembodiments, the fluid pressure can be selected to control the diameterof the hole so that a single reamer can ream holes of differentdiameters. Also, the fluid pressure can be selected to compensate forwear of the cutting blade. Also, the fluid pressure can be selectivelycontrolled as the hole is being reamed to control the longitudinalprofile of the hole, or to compensate for workpiece deformation whichcan occur as the hole is reamed.

[0034] In another exemplary embodiment, the tool includes a workingportion with a working member, a side surface and an end surface. Theworking portion includes a passage passing through the side surface andthe end surface. The tool further includes at least one seal adapted torestrict fluid flow through the side surface and the end surface and atleast partially defining a pressure chamber. The working member isadapted to be selectively pivotally positioned to any of a variety ofworking positions in use by selectively pressurizing the pressurechamber.

[0035] Still another exemplary embodiment of the invention involves amethod of removing material from a workpiece. With such method, a toolis provided including a working portion with a working member. Fluidpressure is provided to pivot the working member outwardly to at leastone of a plurality of alternative use positions. The tool is then movedtowards the workpiece such that the working member selectively removesmaterial from the workpiece as the working member is applied to theworkpiece. It will be understood that the tool can be moved before,during and/or after adjustment of the working member to the useposition.

[0036] Still other objects of the present invention will become readilyapparent to those skilled in this art from the following descriptionwherein there is shown and described an exemplary embodiment of thisinvention, simply by way of illustration, of one of the best modescontemplated for carrying out this invention. As will be realized, theinvention is capable of other different embodiments, and its severaldetails are capable of modification in various aspects all withoutdeparting from the invention. Accordingly, the drawings and descriptionswill be regarded as illustrative in nature, and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

[0037] The present invention as set forth in the detailed descriptionwill be more fully understood when viewed in connection with thedrawings in which:

[0038]FIG. 1 shows a schematic elevational view of a machining centerand tool of the present invention with through spindle coolant fluidcommunication between a tool of the present invention and a fluidsupply;

[0039]FIG. 1A is a cross-sectional view of a tool according to thepresent invention;

[0040]FIG. 2 is an end view of the tool of FIG. 1;

[0041]FIG. 3 is a partial cross-sectional view of an alternativeembodiment of a to tool according to the present;

[0042]FIG. 4 is an end view of the tool of FIG. 3;

[0043]FIG. 5 is a partial cross-sectional view of an alternativeembodiment of a tool according to the present invention;

[0044]FIG. 5A is a partial cross-sectional view of another alternativeembodiment of a tool according to the present invention;

[0045]FIG. 5B is a partial cross-sectional view of yet anotheralternative embodiment of a tool according to the present invention;

[0046]FIG. 6 is an end view of the tool of FIG. 5;

[0047]FIG. 7 is a cross-sectional view of another alternative embodimentof a tool according to the present invention;

[0048]FIG. 8 is a side view of yet another embodiment of a toolaccording to the present invention;

[0049]FIG. 9 shows the tool boring a hole in a workpiece;

[0050]FIG. 10 shows the tool boring a hole in a workpiece;

[0051]FIG. 11 shows the tool boring a hole in a workpiece;

[0052]FIG. 12 shows an embodiment of a tool with strain relief;

[0053]FIG. 13 shows a portion of a blade of the tool which acts as asupport member due to its wide cylindrical margin;

[0054]FIG. 14 shows an exploded prospective view of another alternativeembodiment of the tool according to the present invention;

[0055]FIG. 15 shows an elevational view of the tool of FIG. 14;

[0056]FIG. 16 shows a side elevational view of a blade cartridge usedwith the present invention;

[0057]FIG. 17 shows a sectional view taken along line 17-17 of the toolof FIG. 15;

[0058]FIG. 18 is a partial view of a tool with a jacket in accordancewith another embodiment of the present invention;

[0059]FIG. 19 is a partial sectional view taken along line 19-19 of thetool of FIG. 18;

[0060]FIG. 20 is a partial exploded perspective view of the tool of FIG.18;

[0061]FIG. 21 is a partial view of a tool with an elongated end seal inaccordance with yet another embodiment of the present invention;

[0062]FIG. 22 is a sectional view taken along line 22-22 of the tool ofFIG. 21;

[0063]FIG. 23 is an exploded perspective view of the tool of FIG. 21;

[0064]FIG. 24 is a rear view of an end cap in accordance with thepresent invention;

[0065]FIG. 25 is a schematic illustration of a portion of a method ofboring as the tool is inserted in accordance with the present invention;

[0066]FIG. 26A is a schematic illustration of a portion of a method ofremoving the tool without contacting the interior service of the bore inaccordance with the present invention;

[0067]FIG. 26B is a schematic illustration of a portion of a method ofboring while removing the tool in accordance with the present invention;

[0068]FIG. 27A is a schematic illustration of a portion of a method ofchanging boring diameters as the tool is inserted in the bore; and

[0069]FIG. 27B is a schematic illustration of a portion of a method ofremoving the tool from without contacting the frustoconical surface ofthe bore in accordance with the present invention.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

[0070] Referring now to the drawings in detail, wherein like numeralsindicate the same elements throughout the Figures, FIG. 1 illustratesworking area 10 which typically comprises a machining station 20 and awork head 12 having a workpiece 14 attached thereto using fixtures andtechniques known in the industry. Workpiece 14 is illustrated as asingle exemplary structure having a bore hole or similar hollow interiorportion which requires honing or finishing. In operation, the tool 100and workpiece 14 are generally rotated or moved respectively to eachother as tool 100 is brought into contact with the workpiece 14 (seearrow “Y”) in order to enable machining operations such as honing.

[0071] The present invention may be adapted for use with a machiningstation or center 20 having a machine spindle 24 which can be rotated atvarying speeds by a power source (not shown), and which can quickly andeasily receive and secure one of a plurality of tools for variousoperations (i.e., rotating, vibrating or oscillating). A machiningstation 20 typically has a synchronized system, such as an automatictool changer (not shown), for quickly and easily interchanging andutilizing multiple matching tools at one machining station or center 20,thereby allowing machining station 20 to provide greater utility orrange of operations, (i.e., they are not dedicated to a single operationor use of to a single type of tool).

[0072] Any engaging assembly (e.g., 25) (i.e., clamping or otherwisesecuring) the proximal end 104 of the tool 100 in a generallycantilevered fashion with the machine spindle 24, such as a drawbar, acollet, a mandrel device, or other device known in the industry, can beused, so long as fluid can be provided to the tool 100 adjacent thespindle/tool interface 28 while the tool 100 is in use. An exemplaryengaging assembly 25 allows for quick interchange of tools and provisionof fluid communication between the spindle passage 26 and the fluiddistribution passageway 108 at tool/spindle interface 28 without theneed for separately hooking up hydraulic lines or other fluidconnections. As will be understood, the tool 100 could also be utilizedin conventional applications and dedicated operations as well.

[0073] One embodiment of a tool 100 will now be described with referenceto FIGS. 1A, 2, and 9 to 11. The tool 100 can include a cutting reamer(e.g., head 101, which can be detachably chucked to a spindle 24.Cutting head 101 generally includes a proximal portion 104, a middleportion 106 and a cutting portion 107.

[0074] The tool 100 may comprise a body and is made of a rigid material(e.g., heat treated steel or the like) configured in a longitudinallyextended generally cylindrical shape. The tool 100 can be of any desiredlength, however, it is preferably sufficiently long to accomplish thedesired machining operation. A variety of standard materials availablein the industry can be used to form the tool 100 so that it issufficiently rigid and maintains its structural integrity in the desiredform during the machining operations at rotational speed from about 200to about 20, 000 revolutions per minute, and so that adverse materialdeformation does not occur as fluid pressure in the hollow conduit orfluid distribution system 108 increases to levels from about 200 poundsper square inch (“psi”) to about 1,000 psi (1.38×10⁶n/m² to6.89×10⁶n/m²). Illustrative examples of materials which might be usedinclude aluminum, steel, or the like. For example, an aluminum alloymight be used where there is a need for a lighter weight tool, whichmight be desirable when the tool 100 is interchanged in a machinespindle 24 using an automatic tool changing system.

[0075] The cutting portion 107 can include blade 126 and/or support pad124. When the cutting head 101, is driven to rotate in the angulardirection A about its longitudinal axis L by spindle 24, blade 126 canbe used to drill, cut, ream, bore or otherwise machine an opening,cut-out or hole in a workpiece (e.g., 14), while support pad 124 helpsto support the cutting head 101 within the hole being machined. Morespecifically, support pad 124 can rotate along the inner wall of thehole that is being machined by blade 126, in order to help maintainalignment between the longitudinal axis L of the cutting head 101 andthe central axis of the hole, which is being machined by blade 126,despite the force which the physical interference between the workpiece(e.g., 14) and blade 126 exerts on the cutting head 101.

[0076] This support function of support pad 124 can be especially usefulwhen the depth of the hole being bored is quite long relative to thediameter of the hole. The hole in the barrel of a gun is one example ofthis type of application. The support provided by support pad 124 canalso be important in boring high precision holes, for example holes withclose tolerances on diameter or cylindricity. Some examples of precisionholes are cylindrical bores in engine blocks, spool valves, valvebodies, precision bores and connecting rods, and wrist pin bores.

[0077] Hollow conduit 108 can be provided within the body of tool 100 toextend or run along the longitudinal axis L in a predeterminedarrangement, for example, from proximal portion 104 to the cuttingportion 107. Both the tool 100 and the conduit 108 may be oriented sothat they share the same center longitudinal axis of rotation. As willbe better understood from the description herein, this coaxialorientation of the tool 100 and the conduit 108 may be provided so thatthe interchanging of tools made in accordance herewith (i.e., securingthe tool 100 in place and establishing fluid communication between thespindle passage 26 and the hollow conduit 108) can be accomplishedquickly and automatically upon attachment of tool 100, and to preservebalance in the tool 100 so that eccentricities, which could causevibrations during use, are held to a minimum. In this regard,off-centered routing of hollow conduit 108 within the tool 100 could beemployed, but in such exemplary embodiments, the tubes could be arrangedsymmetrically relative to the tool 100 to preserve balance during highspeed tool rotation.

[0078] Forming the fluid distribution system 108 in the tool 100 andhaving fluid routed therethrough also provides an effective heat sink todissipate thermal energy generated during machining operations, furtherminimizing undue thermal expansion. If the tool 100 were to undergosignificant or uncontrolled thermal expansion, and particularly in aradial direction, the outer diameter of the tool mandrel 100 wouldincrease and could interfere and hamper machining operations.

[0079] Referring back to FIG. 1, the work area 10 also includes a fluidsupply system 11 that generally provides a source of pressured fluid tobe routed through the spindle 24 (via spindle passageway 26) and throughtool 100 (via the fluid distribution system 108). The fluid supplysystem 11, often referred to as a through-spindle coolant or fluidsystem, also generally includes a compressor or other system (not shown)for pumping fluid at the desired pressure and flow rate. Various fluidsupply systems could be used. For instance, each of the embodiments ofthe present invention may comprise or be connected to a fluid supplysystem of one of the types described in U.S. patent application No.09/392,091 filed Sep. 8, 1999, which is herein incorporated byreference.

[0080] The spindle passage 26 has a distal end which can provide anautomatically sealing interface with the tool 100 and fluid distributionsystem 108 at the tool/spindle interface 28. This seal might be providedin a variety of structural arrangements, including O-ring, seals and thelike, and its exact structure may vary among particular applications.

[0081] Fluid communication can thereby automatically and immediatelyestablished and maintained between the spindle passageway 26 and fluiddistribution passageway 108 when the tool 100 is engaged and held inplace by the engaging assembly 25 using various assemblies andtechniques known in the industry, as discussed previously. It should benoted that when the tool 100 is not engaged with the engaging assembly25, mechanisms known in the industry (e.g., shut off valves or the like)can be used to terminate the flow of coolant fluid adjacent the end ofthe spindle passage 26.

[0082] Conduit 108 can branch into a plurality of delivery conduits forassisting in delivering fluid to either the workpiece (e.g., 14) theblade 126 and/or the support pad 124. The delivery of cooling orlubricating fluid to the machining area can assist in the dissipation ofthermal energy build up in the tool 100 and/or workpiece 14 (whichresulted from machining operations), the lubrication of machiningoperations, and/or facilitate chip or particle removal. FIG. 1Aillustrates delivery conduit including side conduits, such as supportside conduit 110, blade side conduit 112, and/or exit conduit 114.

[0083] Fluid tight piston 116 can be provided, and can assist inmetering or controlling, or even preventing pressurized fluid fromescaping out of the cutting head 101 through the side conduits, such assupport side conduit 110. Likewise, fluid tight piston 118 can assist inmetering or controlling, or even preventing the pressurized fluid fromescaping from the cutting head 101 through the blade side conduit 112.However, escape conduit 114 may allow pressurized cooling andlubricating fluid to escape from tool 100, so that the cooling andlubricating fluid splashes out of the cutting head 101 in the directionsindicated by the arrows S. (As discussed below in connection with theembodiment exemplified in FIG. 7, in some embodiments of the presentinvention, the piston may allow fluid to leak around the blades and/orsupport members to help provide cooling and to lubrication.)

[0084] The cooling and lubricating fluid which splashes out of escapeconduit 114 (and also side conduits, as discussed above) serves toassist in cooling the tool 100 and workpiece 14 in order to help counteror dissipate heat build-up caused by the machining operation. Thecooling and lubricating fluid also helps to lubricate the interfacebetween support pad 124 and the inside wall of the hole being bored, sothat support pad 124 moves more easily and smoothly along the insidewalls of the hole, and also the interface between the blade 126 and theinside wall of the hole being bored, so that blade 126 moves more easilyand smoothly along the inside walls of the hole. Conventional coolingand lubricating fluids, such as emulsified water or soluble coolantfluid, protein based water soluble coolant fluid, straight oil, mixturesthereof, or other available machining fluids can be used as the coolantfluid.

[0085] Blade side piston 118 may reside in blade side conduit 112. Thepressurized cooling and lubricating fluid in the blade side conduit 112assists in pushing blade side piston 118 generally radially outwardlyagainst a lower part of blade cartridge 122. Because the blade cartridge122 is provided with a slot 123, the lower part of blade cartridge 122(and the attached blade 126) will move in the direction generallyindicated by R′ when pushed by blade side piston 118.

[0086] In this way, unlike many conventional tools, the blade cartridge122 and blade 126 are selectively biased in the radial direction, withthe amount of bias being determined by the fluid pressure in blade sideconduit 112. The fluid pressure in blade side conduit 112 is primarilydetermined by how fast fluid is pumped into the hollow conduit 108 bythe pump (P) which supplies fluid from supply 11 to conduit 108.Therefore, the bias or position of blade 126 can be controlled bycontrolling the speed and pressure of the pump P.

[0087] More particularly, when the fluid in blade side conduit 112 is ata relatively high pressure, this high pressure will serve to push bladeside piston 118 and the blade 126 relatively far out in the directionR′. (An example of this is shown in FIG. 10.) On the other hand, whenthe fluid pressure in the blade side conduit 112 is relatively low, theblade side piston 118 and the blade 126 will be pushed in the directionR′ to a lesser extent, if at all. (An example of this is shown in FIG.9.)

[0088] In either case, the location of the blade 126 with respect to theR′ direction will be determined by the balance between the fluidpressure pushing in the R′ direction, the forces pushing in the counterR′ direction, and/or the centrifical force generated by rotation of tool100. Specifically, the spring force of the slotted blade cartridge 122and the force exerted by the workpiece on blade 126 will tend to pushthe blade 126 in the counter R′ direction.

[0089] If the spring force of blade cartridge 122 and the amount ofcounter R′ force exerted on blade 126 by the workpiece remains fairlyconstant, then the location of the blade in the R′ direction can beselected and controlled by controlling the bias, which can beaccomplished by controlling the fluid pressure in blade side conduit 112and/or rotational speed of the tool 100. As such, the fluid pressure inblade side conduit 112 can be selected to determine the radius of thehole being machined and/or selected to compensate for wear of the blade126 since the displacement direction R′ of the blade 126 issubstantially the same as the radial direction R, at least over thelimited travel range of blade 126.

[0090] Support pad 124 can be mounted on support cartridge 120, and mayinclude a slot 121 that can permit the lower part of the blade cartridge120 and the support pad 124 some range of travel in the R″ direction(which is substantially the same as the radial direction R for thelimited range of travel allowed by support cartridge 120). Fluidpressure in support side conduit 110 tends to push support side piston116 against the lower part of support cartridge 120, thereby working tobias support pad 124 in the R″ direction. Therefore, the support pad 124can be selectively biased in a manner similar to the blade member 126.Alternatively, a blade, similar to blade 126, can be mounted on supportcartridge 120. A second blade can assist in supporting tool 100, and canassist in removing material from workpiece 14.

[0091] The spring force of support cartridge 120 and normal forcesexerted by the workpiece (e.g., 14) on support pad 124 will tend to pushback in the counter R″ direction. The location of support pad 124 in theR″ direction will therefore be determined by the balance of theseforces. By controlling the bias of the support pad 124, its location canbe controlled during machining operations.

[0092] Tool 100 can compensate to some degree for differences in wearbetween blade 126 and support pad 124. In use, both blade 126 andsupport pad 124 will wear to some extent due to physical interferencebetween these parts 124 and 126, respectively, and any workpiece (e.g.,14). Generally, blade 126 will wear faster than support pad 124 becauseblade 126 actually does the machining of workpieces (e.g., 14). Ofcourse, in a conventional reamer, if the blade member wears faster thanthe support member(s), then the diameter and/or the alignment of theholes cut by the conventional reamer will generally be adverselyaffected.

[0093] However, if tool 100 is a reaming tool and if the blade 126 losesmaterial through wear, then the biasing fluid pressure in blade sideconduit 112 will tend to push blade 126 further out in the R′ directionin order to compensate for this wear to some extent, and to maintainblade 126 at an appropriate radial location. Similarly, if support pad124 loses material through wear then the biasing fluid pressure insupport side conduit 110 will likewise push support pad 124 out furtherin the R″ direction in order to compensate for the support side wear tosome extent. Not only does this feature of the present invention helpenhance hole precision and alignment, it also may allow more prolongeduse of blades and/or support members by effectively compensating for anincreased degree of wear.

[0094] Turning now to FIGS. 9 and 10, tool 100 of the present inventioncan be used to machine (e.g., ream) holes of different or varyingdiameters. In FIG. 9, the biasing fluid pressure in conduit 108, bladeside conduit 112 and support side conduit 110 is maintained at arelatively low level so that the blade 126 and the support pad 124 arenot pushed out very far in the R′ and R″ directions, respectively. Underthese conditions, a hole machined by tool 100 will have a relativelysmall diameter.

[0095] However, by increasing the biasing fluid pressure in the conduits108, 110 and 112, as shown in FIG. 10, the blade 126 and support pad 124will be pushed further out in the R′ and R″ directions, respectively.This can result in a relatively larger diameter hole. No change in thetool hardware is necessary to accomplish this, rather only the pressureof the supply fluid must be adjusted. Of course, it is generally easierto control the pressure of the cooling and lubricating fluid (bycontrolling speed and/or pressure of a pump) than it is to changehardware, so the tool 100 according to the present invention objectivewill generally increase efficiency and productivity in applicationswhich require holes of different diameters.

[0096] Also, although the blade 126 and support pad 124 have a limitedrange of travel and an accordingly limited range of possible holediameters, fewer tool cutting heads (e.g., 101) will generally benecessary for a given application compared to tool heads, which arecapable of machining only one hole diameter.

[0097] The relative range of travel between the blade 126 and thesupport pad 124 can vary according to the particular application. Forexample, finishing tools can have a relative range of adjustment toallow the machining diameter to vary around 250 microns. Roughing toolsmay have a larger range of adjustment to allow the machining diameter tovary around 500-1000 microns. The greater amount of adjustment forroughing tools is desirable due to the relatively high level of wearexperienced by the tool and is permitted since a lower level ofprecision is necessary during roughing procedures.

[0098] Turning now to FIGS. 9-11, tool 100 can be used to compensate formaterial deformation in the workpiece. FIG. 9 exemplified a hole beingmachined in workpiece 14 by tool 100. In the machining operationexemplified by FIG. 9, the fluid pressure in conduits 108, 110, 112 andthe radial location of blade 126 and support pad 124 are maintained at agenerally constant value. Under these conditions, workpiece 14 willgenerally bow inward near the top of the hole at the location denoted byreference numeral 16, due to material properties inherently present inworkpiece 14.

[0099] As exemplified in FIGS. 10 and 11, compensation for thisphenomenon can be effected by tool 100. When tool 100 is reaming the topof the hole, the biasing fluid pressure in conduits 108, 110, 112 isadjusted so that blade 126 and support pad 124 are pushed out a bitfurther in the radial direction R. At first, this results in the holediameter being somewhat larger at the top of the hole as denoted byreference numeral 18. Then, as shown in FIG. 11, as the tool 100machines (e.g., reams) further down into the workpiece 14, the biasingpressure in conduits 108, 110, 112 is gradually decreased so that theblade 126 and support pad 124 gradually retract to some degree to matchthe nominal diameter of the hole being machined as the tool 100 movesfurther down into the workpiece 14. While this is occurring, the top ofthe hole 16 will spring back to some degree to occupy the positiondenoted by reference 18. In this way, the top of the hole can take onthe nominal hole diameter, because it was machined out to a somewhatlarger diameter.

[0100] Of course, in order to accomplish the machining operation shownin FIGS. 10 and 11, the fluid pressure must be continually and carefullycontrolled with respect to the longitudinal location of the tool 100within the workpiece 14. Appropriate control of the fluid pressure canbe empirically determined and written into software which controls thetool 100. On a related note, tool 100 can be also used to machine holesin a workpiece 14 which do not have a constant diameter over or alongtheir entire length. The fluid pressure can be controlled as themachining occurs so that various portions of the hole have larger orsmaller diameters as desired. For example, tool 100 can be used to bothream a hole and provide a facing for the hole or a counter sink for thehole at the front and/or back of the workpiece 14.

[0101] Another embodiment of a tool 200 according to the presentinvention is exemplified in FIGS. 3 and 4. In tool 200, hollow conduit208, blade side conduit 212, escape conduit 214, blade side piston 218,blade side cartridge 222 and blade 226 are similar to the correspondingelements of tool 100. Support members 230 and 232, respectively, areprovided, mounted or otherwise affixed along the cutting portion 207 oftool 200 in a manner similar to that found in conventional tools.

[0102] While tool 200 does not provide all of the flexibility of thepreviously-discussed biased support pad embodiment exemplified in tool100, it is somewhat simpler in construction and may be appropriate forapplications which do not cause much wear on support members 230 and232, respectively. In tool 200, however, wear on the blade 226 can stillbe effectively compensated by appropriate adjustment of the fluidpressure in conduits 208, and 212, respectively.

[0103] Another alternative embodiment of a tool 300 according to thepresent invention is exemplified by FIGS. 5 and 6. In tool 300, acentral conduit 308 can be provided and extends along the tool 300 tothe cutting portion 307 where it terminates in fluid communication witha slot 338 disposed across the cutting portion 307. Blade 326 can beprovided on one side of the slot 338, while support member 330 can beprovided on the opposite side of slot 338 (e.g., FIG. 6). The portion ofthe cutting portion 307 which includes blade 326 is called blade side334. The other portion of the cutting portion 307 having support member330 affixed thereto is called support side 336.

[0104] As with all of the exemplary embodiments having a slotted cuttingor working portion, the slot may be have many thicknesses and shapes inorder to divide the working portion into two or more sections. In someexemplary examples, the slot may have a small thickness (e.g., 0.01inches wide). The slot can be created by many exemplary processes. Forinstance, the slot could be created by a wire EDM process, a slottingsaw, milling, or other process.

[0105] It will be appreciated that thicknesses of larger or smaller than0.01 inches could also be used. A slot with a smaller thickness may bedesirable to minimize fluid loss during use of the tool while a slotwith a larger thickness can be used in situations where a predeterminedamount of fluid loss is desirable (e.g., in situations where additionalcooling, lubrication, and/or chip removal, etc., is desired).

[0106] In operation, cooling and lubricating fluid can be pumped downconduit 308 and into slot 338. Depending on the pressure of the fluid,blade side 334 and support side 336 will be biased away from each otherto a greater or lesser extent. More specifically, blade side 334 will bebiased in the R′ direction by the fluid pressure, while support side 336will be biased in the R″ direction by the fluid pressure. This, in turn,causes the blade 326 and the support member 330 to be pushed in the R′and R″ directions, respectively, thereby allowing control of the radialpositions of the blade 326 and support member 330. In this way, theradial position of the blade member 326 and support member 330 can becontrolled by controlling fluid pressure in the conduit 308 and slot338.

[0107] In tool 300, an area of removed material 340 in the body of tool300 helps to allow relative radial deflection of the sides 334 and 336,respectively. Also generally J-shaped slots 342 and 344, respectivelyhelp allow the sides 334 and 336, respectively to separate in the radialdirection (e.g., R′ and/or R″) under the influence of cooling fluidpressure. A slight modification of this embodiment is exemplified inFIG. 12. FIG. 12 illustrates head 600 with blade 626 and support pad630. Slot 638 can include an alternative configuration, and/or caninclude a strain relief portion 642 to help provide strain relief oftool 600 in use. As will be appreciated by those skilled in theindustry, other shapes and configurations of slots (e.g., 338) can beprovided in the body of tool 300 in keeping with the teachings and scopeof the present invention.

[0108] The tool 300 may also include a seal along the longitudinal edgesthereof to minimize coolant loss out of the tool 300, to assist inselectively biasing the tool 300, and to assist in directing fluidtoward the end of cutting portion 307 of to the tool 300. In oneembodiment, tool 300 may be provided with bore holes 345 in the body oftool 300 generally along the longitudinal length thereof and positionedtoward the edge thereof. Holes 345 can be filled or plugged with acorresponding shaped plug (e.g., generally longitudinally extending) 346to effectively seal the slots 338 along their respective edges.

[0109] Furthermore, a seal 666 (such as an o-ring) and an end cap 668may be provided on and releasably attached to the end of tool 600 tofurther assist in creating a pressure chamber within the tool 600 forselectively biasing the blade 626 and/or support 630 (which also can beanother cutter or blade) radially outwardly for desired machiningoperations. So that tool 600 can be biased as desired, exemplaryembodiments of the present invention may include an end cap 668 attachedwith at fastener 670 at one location to either the blade side 634 or thesupport side 636 of the tool 600. It will further be appreciated thatthe end cap 668 could be attached in both locations, with at least oneof the locations having a slot or other mechanism to allow the fastenerto side relative to the end plate as the blade side 634 and support side636 expand relative to one another. The fastener may be a screw, bolt,or other suitable attachment means known in the machine industry.

[0110] Another alternative exemplary embodiment of a tool 1100 accordingto the present invention is exemplified in FIG. 5A . The tool 1100 issimilar in construction to tool 300 described in relation of FIGS. 5 and6 above and contains the same corresponding parts and operates in asimilar manner. For instance, although not shown, it will be understoodthat tool 1100 includes bore holes and plugs similar to the bore holes345 and the plugs 346 as illustrated in FIG. 6. Furthermore, althoughnot shown, the tool 1100 may also include a seal and end cap, such asseal 666 and end cap 668 described in relation of FIGS. 5 and 6 above.In tool 1100, a central conduit 1108 can be provided to extend along thetool 1100 to a working portion 1107. The working portion 1107 is theportion of the tool adapted to remove material from the workpiece. Thecentral conduit 1108 is in fluid communication with slot 1138 disposedalong the working portion 1107.

[0111] As depicted in FIG. 5A, the slot 1138 is illustrated as beingoffset a predetermined distance D from the axis L according to theparticular application as desired. For instance, the slot 1138 mightextend substantially within the blade side 1134 of the working portion1107, thereby bifurcating the working portion 1107 into sections withdifferent cross sectional areas. Bifurcating the working portion 1107 inthis manner allows the blade 1126 to be biased in the R′ direction arelatively greater distance than the support member 1130 travels in ther″ direction upon pressurization. Biasing the blade side 1134 a greaterdistance than the support side may better compensate for the greaterwear experienced by the working member 1126. As the working member 1126wears away during use, the blade side 1134 can more easily bias outwardto compensate for the worn away portions of the working member 1126. Incontrast, the support member 1130 can remain relatively stationary whichmay be desirable due to the high wear resistance of the support member1130.

[0112] A J-shaped slot 342A can extend upwardly in the side containingthe blade in order to permit further extension of the blade in the R′direction while reducing stress concentrations. Although not shown, itis understood that an additional J-shaped member, such as J-shapedmember 344 illustrated in FIG. 5, could be provided within the tool 1100in order to permit further extension of the support member 1130 in ther″ direction and/or to reduce stress concentrations. In addition,although not shown, the slot 1142 could extend substantially in thesupport side 1136 rather than the blade side 1134 in order to cause thesupport member 1130 to travel a larger distance than the blade 1126.

[0113] In an exemplary operation therefore, fluid (e.g., cooling andlubricating fluid) can be pumped down the conduit 1108 and into the slot1138. As depicted in the embodiment illustrated in FIG. 5A, depending onthe pressure of the fluid, the blade side 1134 will be biased away fromthe support side 1136 in the direction R′. The support side 1136 will bebiased to a smaller extent, if at all, in the direction r″. In thismanner the fluid pressure acts to allow control of the radial positionof the blade 1126 relative to the support side 1136. As with the otherembodiments of the invention, the support member 1130 could compriseanother blade 326 or a plurality of blades and/or supports. Although notshown, it is understood that the slot of the other exemplary embodimentsdescribed herein could also be offset from its axis according to theparticular application as desired.

[0114] The various slotted embodiments of the present invention could beprovided with one or more seals and may even be designed without a seal.Embodiments including a seal can be used to restrict, or prevent, fluidflow from the tool. For example, one or more seals could be used torestrict, or prevent, fluid flow from the side(s) and/or end of thetool. For instance, the embodiment illustrated in FIGS. 5 and 6illustrate at least one seal (i.e., plugs 346) used to restrict, orprevent, fluid flow from the side of the slot 338. In this instance,fluid may be substantially prevented through the sides of the tool whilebeing permitted through the end of the tool. The fluid could further berestricted or prevented with an end cap and/or seal as described inrelation to many of the following exemplary embodiments of slottedtools. It will further be understood that the end cap and/or seal couldbe provided without sealing the sides (e.g., with plugs). Allowing apredetermined amount of fluid might be desirable for lubrication, heatreduction and chip removal. Limiting the fluid flow might further berequired to enable the tool to bias the working member or bladeoutwardly.

[0115] The slotted tools of the described examplary embodiments mightalso be provided without any seals as long as the tool is configured toallow pressure build up to allow proper biasing of the working member orblade and/or support member, if provided. For example, the slot geometry(e.g., a slot with an irregular geometry) could be used to interferewith, and therefore restrict fluid flow. Moreover, the slot thicknesscould be further reduced to the point where the seals would not benecessary.

[0116]FIG. 5B depicts a tool that can function without any sealingmembers. The tool is fabricated with little, if any, clearance betweenthe first side 1434 and the second side 1436 of the working portion1407. As shown in FIG. 5B, the first side 1434 and second side 1436 arefabricated separately and then fastened to the shank 1406. For instance,a plurality of fasteners 1411 may be used to connect the first side 1434and the second side 1436 to a shoulder 1409 of the shank. It will beunderstood that other methods could be used to attach the first andsecond sides to the shank such as welding, brazing, etc. Accordingly,the first side 1434 and second side 1436 are arranged such that there islittle or no clearance between the side surface 1435 of the first side1434 and the side surface 1437 of the second side 1436. In oneembodiment, the first side surface 1435 abuts the second side surface1437.

[0117] In use, pressurized fluid is introduced through conduit 1408 suchthat it travels to the working portion 1407. The pressure causes apredetermined biasing of the first side 1434 and working member 1426attached thereto, relative to the second side 1436 and support member1430 attached thereto. The pressure can be changed to vary the effectivediameter of the tool 1400. As with all of the embodiments of the presentinvention, the support member 1430, if provided, can be replaced withone or more support members and/or working members or blades.

[0118] Yet another embodiment of a tool 400 is exemplified in FIG. 7. Inexemplary tool 400, conduit 408 extends along the center of the tool 400to side conduits, e.g., support side conduit 410 and/or blade sideconduit 412. The fluid in support side conduit 410 will push on and biassupport pad 424 in the radial direction R. Similarly, fluid pressure inblade side conduit 412 will push on and bias blade cartridge 422 andblade 426 in the radial direction R. In this way, fluid pressure can beused to control the radial location of the blade 426 and support pad424. A stop 425 should be provided to ensure that the blade cartridge422 and/or support pad 424 included in the cutting portion 407 are notpushed entirely out of the head by the fluid pressure.

[0119] In tool 400, some clearance (e.g., 427A) can be provided betweensupport pad 424 and support side conduit 410 so that cooling andlubricating fluid can splash out in the directions indicated by thearrows S. Similarly, clearance (e.g., 427B) can be also provided betweenthe blade cartridge 422 and the blade side conduit 412 so that coolingand lubricating fluid may splash out in the direction indicated by thearrow S. Alternatively, the support pad 424 and blade cartridge 422 maybe constructed as fluid-tight pistons so that fluid escaping isminimized or eliminated to the outside of tool 400. Under thisalternative, the fluid would be used solely for the purpose of biasingblade 426 and/or support pad 424.

[0120] Another embodiment of a tool 500 according to the presentinvention will now be described with reference to FIG. 8. In thisembodiment, the blade 526 and support member 530 can be biased in the R′and R″ directions, respectively, by spring 540 which is located withinslot 538 in the cutting portion 507 of tool 500. Spring 540 is chosen sothat its spring force provides an appropriate amount of biasing force onthe blade 526 and support member 530. The spring 540 can be removed andreplaced with other springs having other characteristics depending onthe desired application. In this way, tool 500 can be used to machineholes of different diameters. For example, a longer spring or a stifferspring will push out blade 526 and support member 530 further in the R′and R″ directions, respectively, resulting in a larger diameter hole.Also, springs 540 can be selected to compensate for wear and tear of theblade 526 and/or support member 530. For example, a longer or stifferspring 540 can compensate for a worn blade 526 and/or support member530.

[0121] It is noted that the biasing force on the blades (e.g., 126)and/or support members (e.g., 130) of tools according to the presentinvention can be at least one order of magnitude higher than the cuttingload or the load caused by friction from the workpiece (e.g., 14). Inembodiments using fluid pressure, a high bias can be effected by makingthe active area of the piston (e.g., interface between the fluid and thepiston) as large as possible.

[0122] It is also noted that support members of tools according to thepresent invention may be shaped identically to the blade member. Forexample, if a reamer head is configured to have three “blades” aroundits circumference, generally the “blade ” which protrudes a small amountfarther in the radial direction will act as a blade by performing mostof the material removal. The other two “blades” will not remove asubstantial amount of material and can act instead as support members.In still further examples, a plurality or all of the blades could bearranged to protrude outwardly such that they all remove material whileeach blade also acts as a support member for the remaining blades.

[0123] Another way to help ensure that a member having a “blade”geometry will act as a support member rather than a blade is to use ablade with a relatively wide cylindrical margin relative to the diameterof the bore. This is shown in FIG. 13, where blade 702 has a widecylindrical margin 704 relative to bore 715. Due to its wide margin,blade 702 does not remove substantially any material from the workpiece14 and acts a support member, rather than as a blade.

[0124] In still further examples, the blade 702 can be arranged toremove a substantial amount of material while also acting as asupporting member for cutting material.

[0125] Turning now to FIGS. 14-17, the present invention can alsoinclude a chip evacuation chamber 852 in the body of a tool forassisting in removing cut particles and/or chips from the machining areain a hole, and from interfering with further machining operations,especially in blind holes. Chamber 852 includes at least inlet 854adjacent the cutting portion 807, a corresponding outlet 858 positionedproximally away from the inlet 854, such as along the middle portion 806and/or proximal portion 804, and a corresponding passageway 856 betweeninlet 854 and outlet 858. The chamber 852 can also have a largerdiameter when machining an aluminum workpiece since the cut particlestend to ball up, and could easily interfere with particle removal orclog the inlet 854, outlet 858, and /or passageway 856.

[0126] One or more blade cartridges 822 and/or support cartridges (see,e.g., FIG. 17) can each be mounted or attached to tool 800 withinchamber 852 using techniques and equipment known in the machine toolindustry. When more than one blade cartridge and blade 826 are used,they can be arranged so that the cut radius of each varies. For example,one of the blade (e.g., 826A) may machine the inner portion of a holewhereas the other blade (826B) may machine the outer portion of thehole. As will be appreciated by those skilled in the art, there shouldbe some slight overlap between blades 826A and 826B, respectively, sothat the hole is machined appropriately, especially in drillingoperations. As exemplified in FIG. 16, when blade cartridge 822 has anextended longitudinal length, which may be need for stability andsupport in machining operation, the shaft 822A of cartridge 822 may betapered to assist in providing for chip removal through chip removalpassageway 852.

[0127] The tool 800 may also include a seal (e.g., plug 846) along thelongitudinal edges (e.g., within holes 845 extending along the edges)thereof to minimize coolant loss out of the tool 800, to assist inselectively biasing the tool 800, and to assist in directing fluidtoward the end of cutting portion 807 of the tool 800. In oneembodiment, as shown in FIG. 14, tool 800 may be provided with boreholes 845 in the body of tool 800 generally along the longitudinallength thereof and positioned toward the edge thereof. Holes 845 can befilled or plugged with a corresponding shaped plug 846 (e.g., generallylongitudinally extending) to effectively seal the slots 838 along theirrespective outer longitudinal edges. As with other exemplary embodimentshaving plugs, an end cap may also be provided to help secure the plugsin place.

[0128] Another alternative embodiment of the tool 900 is illustrated inFIGS. 18-20. A central conduit 908, as best seen in FIG. 19, can beprovided to extend along the tool 900 to a working portion 907. Asillustrated in FIG. 18, the working portion 907 of the tool 900 isbifurcated with a slot 938 extending laterally through the sidewall. Theembodiment of tool 900 includes a seal 980, such as a jacket, orbladder, with an at least partially open end 982 facing the conduit 908and a closed end 983 facing away from the conduit 908. The jacket 980 ispositioned within a cavity 974 defined in the working portion 907 of thetool 900. The jacket 980 acts to at least partially form or sealinglydefine a pressure chamber 975 and is adapted to restrict, orsubstantially prevent, fluid from traveling outwardly through the slot938. An end cap 968, having a first section 976 and a second section 978are shown as being secured with fasteners (see 970 in FIG. 20) to thecutting portion 907 of the tool 900 in order maintain the jacket 980within the cavity 974 while allowing selective radial flexing of thefirst side 934 and the second side 936 of the tool 900 to adjust theeffective working diameter of the tool in use.

[0129] The jacket 980 may include one or more apertures 984 forcommunicating with one or more corresponding escape conduits or passages914 defined in the cutting portion 907 to allow fluid to passtherethrough and be dispensed by a nozzle 915 for lubrication, heatreduction, and/or chip removal adjacent the corresponding working memberor blade 926. As with any of the other embodiments of the inventiondescribed herein, the working member or blade may comprise a cuttingedge (e.g., see the edge of the working member 926). In addition, theworking member or blade may comprise an abrasion surface, or othermember adapted to remove material from a workpiece by cutting, grinding,reaming, boring or other mechanical method. Moreover, the working memberor blade may be replaced by one or more support members, such as supportmember 330 depicted in FIG. 5.

[0130] The jacket 980 can be comprised of flexible materials such asplastic and may be impermeable to the pressurized fluid. In otherembodiments, the jacket 980 might be comprised of a material that is atleast partially permeable to the fluid, such as a fluid permeablemembrane, to provide sufficient resistance to fluid flow in order toallow pressurization of the pressure chamber 975 while allowingpredetermined limited seepage of fluid laterally through the slots 938and/or through the escape conduit or passage 914 for lubrication,cleaning, cooling, etc. In still further embodiments, the jacket 980could be perforated with a plurality of small apertures that restrict,rather than prevent, fluid flow. With a fluid permeable material orfluid restricting structure, the aperture 984 in the jacket 980 may besmaller or nonexistent wherein a restricted amount of fluid may escapethrough the escape conduit or passage 914 is a result of the permeablyof the material and/or the permeable structure of the jacket 980.

[0131] In one exemplary embodiment, the jacket 980 could comprise nylon,such as Delrin nylon, to act as a pressurized jacket or bladder as shownin the figures, especially FIG. 20. In still other examples, the jacketcan comprise a material having comparable modulus and strength of Delrinnylon. In still further examples, it is understood that the jacket canalternatively comprise a material having a different modulus andstrength than that of Delrin nylon. Indeed, it will be appreciated thata wide range of material will be acceptable to create the jacket of thepresent invention as long as the modulus is less than the material ofthe working portion to allow the jacket to expand, and thereby radiallyflex the sides of the working portion. In addition, it is understoodthat the jackets of the present invention may be adapted to allowtransmission and communication of fluid to the escape conduit or passage914 and/or the slot 938.

[0132] The jacket 980, as shown in FIG. 20, may have a generallyhour-glass shape corresponding to the conformation of the cavity 974.The hour-glass shape allows the jacket 980 to accommodate a maximum areain the cavity 974 while still allowing for apertures 973 to be formed inthe working portion 907. Moreover, the non-circular shape simplifiesalignment of the jacket aperture 984 with the escape conduit or passage914, if provided.

[0133]FIG. 20, illustrates an exploded perspective view of the tool 900in accordance with one embodiment of the present invention. To assemblethe tool 900, the jacket 980 is inserted within the cavity 974 with theclosed end 983 facing outwardly and with the aperture 984, if provided,in communication with the escape conduit or passage 914 of the workingportion 907. The first and second sections 976, 978 of the end cap 968are placed over the end of the working portion 907 such that aligningdowels 972 are received in corresponding ones of apertures 971 formed inthe end cap 968 and through corresponding ones of the apertures 977formed in the working portion 907. Next, the end sections 976, 978 arefastened to the working portion 907, for instance with fasteners 970.Fasteners 970 are received within apertures 969 formed in the end capand through threaded tapped holes 973 formed in the working portion 907.The apertures 969 may be counter sunk in order to recess the heads ofthe fastener 970. Blade cartridges 922 with corresponding blades 926 arefastened to the working portion 907.

[0134] Although the slot 938 is illustrated as extending along thecentral plane of the cutting tool 900, it is understood that the slot938 may be offset as illustrated in, for example, FIG. 5A to allow oneof the blades to bias outwardly farther than another blade. In addition,as with all the embodiments of the present invention, the cutter bladecould take the form of a singular cutter edge or could be provided withrough working surface for removing material from the interior portion ofthe workpiece.

[0135] Another exemplary tool 1000 of the present invention is depictedin FIGS. 21-23. FIG. 21 is a partial view of a tool 1000 with abifurcated end having a slot 1038 extending laterally through thecutting portion 1007. The tool 1000 includes at least one seal (e.g.,plugs 1046 and elongated end seal 1066 as best seen in FIGS. 22 and 23)adapted to restrict or prevent fluid flow through the side surface 1009and the end surface 1013 of the working portion 1007.

[0136]FIG. 22 is a sectional view of along line 22 of FIG. 21 andillustrates plugs 1046 inserted into holes 1045 that extend within thecutting portion 1007 at a depth I₂ that is larger than the depth I₁ ofthe slot 1038 to help slow or prevent fluid flow through the lateralslot 1038. As illustrated in FIGS. 22 and 23, the elongated end seal1066 is positioned at the end of the cutting portion 1007 to slow orprevent fluid from escaping through the end of the cutting portion 1007.The end cap 1068 includes a first end cap section 1076 and a second endcap section 1077. The end cap sections 1076,1077 are shown as beingfastened to or otherwise associated with the end of the cutting portion1007 to help position the elongated end seal 1066 and maintain the plugs1046 in functional position.

[0137]FIG. 23 is an exploded perspective view of the tool 1000. Whenassembling one exemplary embodiment of the present invention, the deviceplugs 1046 are inserted into the holes 1045. In one embodiment, the endsurface 1048 of the inserted plugs 1046 would be generally flush withthe end surface 1013 of the working portion 1007. In still anotherembodiment of the present invention, the end surface 1048 of the plugs1046 might extend slightly outwardly from the end surface 1013 of theworking portion 1007 to ensure that the plug 1046 extends entirelywithin the holes 1045 and/or to allow slight compression of the plug1046 by attachment of end cap 1068 to provide excellent sealingproperties. Elongated end seal 1066 is placed over the end surface 1013of the cutting portion 1007 to at least cover a portion of the end slot1039. In one embodiment, as illustrated in FIG. 23, the end seal hasenlarged ends adapted to extend over the end surface 1048 of the plugs1046 to further prevent and/or restrict fluid flow. The first end capsection 1076 and the second end cap section 1078 are thereafter placedover the end surface 1013 of cutting portion 1007 such that alignmentdowels 1072 are positioned within apertures 1071 in the end cap 1068 andapertures 1077 in the cutting portion.

[0138] Moreover, as illustrated in FIG. 24, the reverse side of the endcap sections 1076, 1078 can define a recess 1080 adapted to receive atleast a portion of the elongated end seal 1066. In one embodiment, thedepth of the recess 1080 is slightly less than the thickness of the endseal 1066 to cause compression of the end seal 1066 when the end capsections 1076, 1078 are fastened to the cutting portion 1007, forinstance, with fasteners 1070. The fasteners 1070 can pass throughapertures 1069, such as countersunk bores, to be threaded withinthreaded apertures 1073 defined in the cutting portion 1007. One or morecartridges 1022, with corresponding working members 126, may be fastenedto the cutting portion 1007. In addition, a nozzle 1015 may be insertedinto the escape conduit 1014 to direct fluid adjacent each of theworking members or blades 1026.

[0139] In use, pressurized fluid is supplied through conduit 1008 topressurize a pressure chamber 1075 defined in the working portionbetween the plugs 1046 and the end seal 1066, thereby causing a firstside 1034 and second side 1036 to flex or bias outwardly relative to oneanother and to thereby select and control the effective machiningdiameter of the tool 1000. Fluid may optionally travel through escapeconduit 1014 to be dispensed by nozzle 1015 adjacent the working memberor blade 1026 to provide lubrication, heat control, and/or chip removal.In addition, a relief portion 1042 may also be provided to reduce stresspoints within the tool 1000.

[0140]FIGS. 25, 26A, 26B, 27A, and 27B are provided as examplesillustrating various methods relating to improved and unique proceduresused to remove material from a workpiece with any of the aboveembodiments of the present invention. For illustrative purposes, thetool will be generally referenced with reference character 1200,however, it is understood that any tool mentioned above could be used inone or more of the below explained procedural steps.

[0141]FIG. 25 depicts a method wherein the tool 1200 is expanded to afirst effective machining diameter D_(e1). In addition to providing aworkpiece 14, a tool 1200 is provided with a working portion 1207 and aworking member 1226. Fluid pressure is provided to pivot the workingmember 1226 outwardly to at least one of a plurality of alternative usepositions. As further illustrated in FIG. 25, the tool is moved towardsthe workpiece 14 (i.e., in the direction of the arrow) such that theworking member 1226 removes material from the workpiece at an effectivediameter D_(e1) as the working member 1226 is applied to the workpiece14.

[0142] As depicted in FIG. 26A, fluid pressure may be reduced to allowthe tool 1200 to at least partially pivot the working member 1226 backto a reduced effective diameter or a non-use position, and then the tool1200 is moved away (i.e., in the direction of the arrow in FIG. 26A)without removing additional material from the workpiece. It will beunderstood that the tool 1200 could be further moved away until theworking member 1226 is radially clear of the workpiece 14, andthereafter increasing the fluid pressure to obtain another, greatereffective diameter, and then moving the tool 1200 towards the workpiece14 such that the working member 1226 removes additional material fromthe workpiece 14.

[0143] Alternatively, as illustrated in FIG. 26B, after machining theworkpiece 14 in accordance with FIG. 25, the fluid pressure could beincreased to further pivot and adjust the working member 1226 outwardlyto at least a second use position having a second effective diameterD_(e2). The tool 1200 could then be moved away from the workpiece 14such that the working member removes additional material from theworkpiece 14 as the working member 1226 is moved in a direction awayfrom the workpiece 14.

[0144] It will be further understood that the pressure could be changedduring the machining process of FIG. 25. For instance, once the tool1200 is inserted a predetermined distance, the fluid pressure could beincreased to likewise increase the effective bore diameter, for instancein a stepped manner. Alternatively, the fluid pressure could beconstantly and/or dynamically changed as the tool 1200 is inserted,thereby creating a frustoconical shape.

[0145] As illustrated in FIG. 27A, the tool 1200 could have asubstantially continuously decreasing pressure and correspondingly,decreasing effective working diameter, as the tool is inserted into theworkpiece, thereby creating a frustoconical shape. For instance, thetool can initially be adjusted to an effective diameter D_(e3) to beginthe working process. The fluid pressure could gradually decrease as thetool is moved relative to the workpiece. For example, as shown in FIG.27A, the tool obtains an intermediate effective diameter D_(e4) as thetool is creating the frustoconical cavity. As further illustrated inFIG. 27B, the final cut is made by the tool having a smaller effectivediameter D_(e5) Once finished, as illustrated in FIG. 27B, the fluidpressure could be decreased to prevent removal of additional material asthe tool is moved in a direction away from the workpiece. As illustratedin FIGS. 27A and 27B, a frustoconical cavity can formed with a flaredouter end. It will be understood, however, that using this method and atool of the present invention, a cavity could be formed with afrustoconical shape with an inwardly flared end and/or a reduced outerend by continuously reducing the fluid pressure during the process stepdepicted in FIG. 26B.

[0146] In still other examples, the tools of the present invention canbe used to create a bore having the shape of an hour-glass wherein thetool starts machining the workpiece with a relatively large initialdiameter and then reduces the bore diameter to neck the bore down to aminimum intermediate diameter and thereafter increases the bore diameterto a larger final diameter. In other examples, the tools of the presentinvention could be used to create a substantially “barrel” shaped borewherein the tool starts machining the workpiece with a smaller initialdiameter and then increases the bore diameter to an intermediate maximumdiameter and thereafter decreasing the bore diameter again to a smallerfinal diameter. In one specific example, the “barrel” shape can beapproximated by forming two fructoconical cavities formed in succession.For instance, a first frustoconical cavity could be formed by initiallymachining the workpiece with a first diameter and then increasing thebore diameter to a final larger diameter as the tool machines theworkpiece. Next, the second frustoconical cavity can be formed bydecreasing the bore diameter as the tool still further machines theworkpiece until a final smaller bore diameter is obtained.

[0147] It will be understood that a wide and unlimited variety of borediameters and shapes can be provided by appropriate fluid pressurecontrol to adjust the effective working diameter in any number of waysduring the boring or other working operations. It is thereforeunderstood that a tool 1200 is provided that has a machining diameterthat may be controlled as the tool is reciprocated relative to theworkpiece to define an interior surface of various shapes.

[0148] The foregoing examples and various exemplary embodiments of thepresent invention set forth herein are provided for illustrativepurposes only and are not intended to limit the scope of the inventiondefined by the claims. For example, each of the tools can be provided asa drilling tool, a reaming tool, a boring tool with the ability toprovide counterbores, chambers and other features in a workpiece.Furthermore, the present invention can be used with through holes and/orblind holes. Additional embodiments of the present invention andadvantages thereof will be apparent to one of ordinary skill in the art,and are within the scope of the invention defined by the followingclaims.

What is claimed is:
 1. A tool for removing material from a workpiececomprising: a) a working portion including a working member, a sidesurface and an end surface, wherein the working portion defines apassage passing through the side surface and the end surface, and b) atleast one seal adapted to restrict fluid flow through the side surfaceand the end surface and at least partially defining a pressure chamber,wherein the working member is adapted to be selectively pivotallypositioned to one of a number of working positions by selectivelypressurizing the pressure chamber.
 2. The tool of claim 1 , wherein thepassage passes through the side surface in at least two locations,thereby dividing the working portion into at least two sections.
 3. Thetool of claim 2 , wherein the passage is symmetrically disposed todivide the working portion into at least two sections havingapproximately the same cross-sectional area.
 4. The tool of claim 2 ,wherein the passage is disposed to divide the working portion into atleast two sections, wherein at least two of the sections includedifferent respective cross-sectional areas.
 5. The tool of claim 1 ,wherein the seal comprises at least one plug adapted to be received inan aperture defined in the working portion.
 6. The tool of claim 1 ,wherein the seal comprises at least one elongated end seal locatedadjacent the end surface of the working portion.
 7. The tool of claim 1, further comprising a cavity defined at least partially within theworking portion, and wherein the seal comprises a jacket adapted to bereceived in the cavity.
 8. The tool of claim 7 , wherein the jacketincludes an open end and a closed end wherein the jacket is received inthe cavity such that the closed end is located adjacent the end surfaceof the working portion.
 9. The tool of claim 7 , further comprising atleast one end cap adapted to restrain the jacket within the cavity ofthe working portion.
 10. The tool of claim 1 , further comprising an endcap adapted to restrain the seal relative to the working portion. 11.The tool of claim 10 , wherein the end cap comprises at least two endcap sections.
 12. The tool of claim 10 , wherein a recess is formed inthe end cap to receive a portion of the seal.
 13. A method of removingmaterial from a workpiece comprising the steps of: a) providing a toolincluding a working portion with a working member; b) providing fluidpressure to pivot the working member outwardly to at least one of aplurality of alternative use positions; and c) moving the tool againstthe workpiece such that the working member removes material from theworkpiece as the working member is applied to the workpiece.
 14. Themethod of claim 13 , further comprising the steps of reducing the fluidpressure to allow the working member to pivot back toward a non-useposition and moving the tool away from the workpiece without removingadditional material from the workpiece.
 15. The method of claim 14 ,further comprising the steps of moving the tool away from the workpieceuntil the working member is radially clear of the workpiece, increasingfluid pressure to pivot the working member outwardly to at least asecond use position and again moving the tool towards the workpiece suchthat the working member removes additional material from the workpiece.16. The method of claim 13 , further comprising the steps of increasingthe fluid pressure to further pivot the working member outwardly to atleast a second use position and retracting the tool from the workpiecesuch that the working member removes additional material from theworkpiece at a different effective diameter.
 17. The method of claim 13, further comprising the steps of increasing the fluid pressure tofurther pivot the working member outwardly to at least a second useposition and moving the tool further towards the workpiece such that theworking member removes additional material from the workpiece at adifferent effective diameter.
 18. The method of claim 13 , wherein thefluid pressure is changed while the tool is moving, thereby altering theeffective diameter of the tool as desired.
 19. The method of claim 18wherein the fluid pressure is substantially continuously changed whilethe tool is moving.
 20. The method of claim 18 , wherein the tool formsa frustoconical cavity in the workpiece.